• Journal of Distribution Science
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• v.11 no.8
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• pp.15-23
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• 2013

Purpose - This is a case study aimed at finding a solution for improving the pallet loading efficiency in the process of delivering products through a transshipment using the T-11 and T-12 pallet systems. The study proposes a solution by demonstrating the case of a certain manufacturer A, who aims to reduce the logistics cost by using packaging sizes that are commonly applicable and can improve the compatibility between the T-11 pallet system, designated as the standard pallet in Korea, and the T-12 pallet system, which is commonly used in other foreign countries. The use of common sizes increases compatibility among the two systems and reduces both logistics and environmental costs. Thus, this case study calculates the quantitative benefits of applying common packaging sizes to improve the compatibility between the T-11 and T-12 pallet systems. These systems are considered to be the most important and widely used transportation systems in the global logistics industry. Research design, data, and methodology - This study examined manufacturer A's representative product and delivery system and assessed how manufacturer A was affected by the use of incompatible packaging sizes in the T-11 (1100 mm×1100 mm) and T-12 (1200mm×1000 mm) pallet systems, which were specified in the KS T 1002 standard. In addition, this study analyzed the impact of these packaging sizes on A's logistics cost. The TOPS program (Total Packaging System) was used to simulate pallet loading efficiency,and the main parameter studied was volume, as calculated from length, width, and height. Results - When the sizes of secondary packaging were not compatible across the T-11 and T-12 pallet systems, a reduction in loading efficiency was observed, leading to an increase in logistics cost during transshipment. Such low loading efficiencies led to a further loss of efficiency in transportation, storage and unloading. This may have a possible environmental impact with high social expenses, such as increased CO₂ emissions. Hence, this study proposed that the KS T 1002 standard be amended to include 21 packaging sizes, including 7 sizes of the 600 mm×500 mm category, which are compatible with both the T-11 and T-12 pallet systems. Conclusions - This study found that the 69 standard sizes under the T-11 pallet system and the 40 standard sizes under the T-12 system in the KS T 1002 standard can be simplified and reduced to 21 mutually compatible packaging sizes, enabling logistics standardization and reducing national-level logistics costs. If the government pays attention to this study and considers the standardization of common sizes for the T-11 and T-12 pallet systems and amends the KS T 1002 standard, this study will deliver practical value to the global logistics industry, apart from being of academic significance.

• Journal of Korea Port Economic Association
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• v.22 no.1
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• pp.1-15
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• 2006

This paper analyzes how levels of logistics standardization are related to logistics costs. The study surveyed ratios of standard pallet use in order to measure levels of firms' standardization in logistics management. Research focused on how firms' logistics costs were related to their levels of logistics standardization and ratios of standard pallet use. After measuring use of standard pallets and logistics costs, optimal levels of logistics standardization were estimated based on survey data. Logistics costs and standardization were more related to labor than to freight volume or export. Results indicated that firms could reduce logistics costs by raising levels of logistics standardization; optimal levels of standard pallet use out of Korean firms' total manufacturing cargo volume were estimated at 44.26% for multi-standard pallets and 57.99% for a single standard pallet (a unit load system). The study demonstrated that adopting a single standard pallet results in better cost saving logistics systems than use of multi-standard pallet types. These results may explain why firms pursue standardization in logistics systems.

• Journal of Distribution Science
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• v.13 no.7
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• pp.41-51
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• 2015

Purpose - This study analyzes loading efficiency by loading pattern for package standardization and reduction of logistics costs, along with the creation of revenue for the revenue review panel (RRP) of Membership Wholesale Clubs (MWC). The study aims to identify standard dimensions that can help improve the compatibility of the pallets related to display patterns preferred by the MWC and thereby explore ways to enhance logistics efficiency between manufacturers and retailers through standardization. Research design, data, and methodology - The study investigates and analyzes the current status based on actual case examples, i.e., manufacturer A and Korea's MWC (A company, B company, and C company), and thus devises improvement measures. To achieve this, the case of manufacturer A delivering to MWC was examined, and the actual pallet display patterns for each MWC were investigated by visiting each distribution site. In this study, TOPS (Total Optimization Packaging Software, USA) was used as the tool for pallet loading efficiency simulations the maximum allowable dimension was set to 0.0mm to prevent the pallet from falling outside the parameters, and the loading efficiency was analyzed with the pallet area. In other words, the study focused on dimensions (length x width x height) according to the research purpose and thereby deduced results. Results - The analysis of pallet loading patterns showed that the most preferred loading patterns for loading efficiency according to product specification, such as pinwheel, brick, and block patterns, were used in the case of the general distribution products, but the products were configured with block patterns in most cases when delivered to MWCs. The loading efficiency by loading pattern was analyzed with respect to 104 nationally listed standard dimensions. Meanwhile, No.51 (330 × 220mm) of KS T 1002 (1,100 × 1,100mm) was found to be the dimension that could bring about an improved loading efficiency, over 90.0% simultaneously in both the T-11 and T-12 pallet systems in a loading pattern configuration with the block pattern only, and the loading efficiency simulation results also confirmed this as the standard dimension that can be commonly applied to both the T-11 pallet (90.0%) and the T-12 pallet (90.7%) systems. Conclusions - The loading efficiency simulation results by loading pattern were analyzed: For the T-11 pallet system, 17 standard dimension sizes displayed the loading efficiency of 90.0% or more as block patterns, and the loading capacity was an average of 99.0%. For the T-12 pallet system, 35 standard dimension sizes displayed the loading efficiency of more than 90% as block patterns (the average loading efficiency of 98.6%). Accordingly, this study proposes that the standard dimensions of 17 sizes with the average loading efficiency of 99.0% should be applied in the use of the T-11 pallet system, and those of 35 sizes with the average loading efficiency of 98.6% should be reviewed and applied in the use of the T-12 pallet system.

• Journal of Korean Society of Industrial and Systems Engineering
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• v.41 no.4
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• pp.59-69
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• 2018

This study deals with the case study on the pallet quantity determination problem for the flexible manufacturing system producing 32 different types of aircraft wing ribs which are major structures of an aircraft wings. A Korean company has constructed the WFMS (wing rib flexible manufacturing system) that is composed of several automated equipments such as the 5-axis machining centers, the RGV (rail guided vehicles)s, the AS/RS (automated storage and retrieval system), the loading/unloading stations, and so on. Pallets play a critical role in the WFMS to maintain high system utilization and continuous work flow between 5-axis machining machines and automated material handling devices. The discrete event simulation method is used to evaluate the performance of the WFMS under various pallet mix alternatives for wing rib manufacturing processes. Four performance measures including system utilization, throughput, lead-time and work in process inventory level are investigated to determine the best pallet mix alternative. The best pallet mix identified by the simulation study is adopted in setting up and operating a real Korean aircraft parts manufacturing shop. By comparing the real WFMS's performances with those of the simulation study, we discussed the cause of performance difference observed and the necessity of developing the CPS (cyber physical system).

• Journal of the Korean Operations Research and Management Science Society
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• v.23 no.4
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• pp.75-86
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• 1998

We address the problem of determining the optimal processing times and pallet/fixture allocation in Flexible Manufacturing systems in order to minimize tool cost while meeting throughput targets of multiple part types. The problem is formulated as a nonlinear program superimposed on a closed queueing network of the FMSs under consideration. A numerical example reveals the potential of our approach for significant cost saving. We argue that our model can be Integrated Into the process planning system of an FMS to generate efficient process plans quickly.

• The Journal of The Korea Institute of Intelligent Transport Systems
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• v.8 no.4
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• pp.73-83
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• 2009

Recently, various studies regarding introduction of RFID have been implemented in many industries including logistics field. The objective of this study are (i) to analyze an economical effect due to the introduction of RFID on ULS(Unit Load System) Pallet, (ii) to develop a model to estimate cost of RFID introduction, and (iii) to establish a foundation for activating introduction of RFID to the logistics field in order to increase efficiency. This study utilized data regarding fifty logistics companies' awareness of RFID usage. The result of the economical analysis showed B/C of 2.766 and NPV of 2.6 billion won, which implies significant benefit to the logistics industry. This study is meaningful in that it is the first study to quantitatively estimate the effect of RFID introduction on ULS pallet in Korea.

• Journal of Institute of Control, Robotics and Systems
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• v.21 no.10
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• pp.930-935
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• 2015

An unmanned forklift requires precise positioning and pallet detection. Therefore, conventional unmanned forklifts use high-cost sensors to find the exact position of the pallet. In this study, a docking algorithm with two cameras is proposed. The proposed method uses vision data to extract the angle difference between the pallet and the forklift. Then the control law is derived from the extracted angle for successful docking. The extracted angle is compared with the actual angle in the real environment. The control law is tested with the Lyapunov stability test and Routh-Hurwitz stability criterion. Through various experiments, the proposed docking algorithm showed the success rate high enough for real-life applications.

• Structural Engineering and Mechanics
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• v.83 no.6
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• pp.745-756
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• 2022

This study aims to determine the cause of the load resistance loss in storage racks that can be attributed to external forces such as earthquakes and to improve safety by developing reinforcement systems that can prevent load resistance loss. To this end, a static cyclic loading test was performed on pallet racks commonly used in logistics warehouses. The test results indicated that a pallet rack exposed to an external force loses more than 50% of its load resistance owing to the damage caused to column-beam joints. Three reinforcement systems were developed for preventing load resistance loss in storage racks exposed to an external force and for performing differentiated target functions: column reinforcement device, seismic damper, and viscoelastic damper. Shake table testing was performed to evaluate the earthquake response and verify the performance of these reinforcement systems. The results confirmed that, the maximum displacement, which causes the loss of load resistance and the permanent deformation of racks under external force, is reduced using the developed reinforcement devices. Thus, the appropriate selection of the developed reinforcement devices by users can help secure the safety of the storage racks.

• Journal of the Korean Operations Research and Management Science Society
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• v.29 no.4
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• pp.175-187
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• 2004

We consider the simultaneous selection of part routes for multiple part types in Flexible Manufacturing Systems (FMSs). Using an optimization framework we investigate two alternative route assignment policies. The one, called routing mix policy in the literature, specifies the optimal proportion of each part type to be produced along its alternative routes, assuming that the proportions can be kept during execution. The other one, which we propose and call pallet allocation policy, partitions the pallets assigned to each part type among the routes. The optimization framework used is a nonlinear programming superimposed on a closed queueing network model of an FMS which produces multiple part types with distinct repeated visits to certain workstations. The objective is to maximize the weighted throughput. Our study shows that the simultaneous use of multiple routes leads to reduced bottleneck utilization, improved workload balance, and a significant increase in the FMS's weighted throughput, without any additional capital investments. Based on numerical work, we also conjecture that pallet allocation policy is more robust than routing mix policy, operationally easier to implement, and may yield higher revenues.

• Journal of Korea Port Economic Association
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• v.25 no.3
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• pp.1-20
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• 2009

A survey to pallet users was conducted in an aspect of the efficiency and benefit. The questionnaire identified the preference about the main variables such as price, size, conformity, material, which are the criteria of the users' choice. staffs in the capital region was selected as respondents and Cluster Analysis and Simulations was carried out with Conjoint Analysis. The result shows that the variables of material and conformity between facilities and products were more important than the variable of size. The respondents prefer the pallets with a various range of products because warehouses should keep a range of products under various condition of temperature. In accordance, the companies that provide a pallet pool service should set up individual marketing strategy by a type of customers so as to maximize the competitiveness in domestic or international markets. Furthermore, supplying standardized pallets should be consistent with the standardization not for individual logistics units, but for whole logistic systems. To achieve this, it requires the compatibility amongst a range of logistics activity participants by their characteristics.